Saga of the Rotten Door - Woodworking Talk - Woodworkers Forum
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post #1 of 3 Old 11-07-2019, 10:04 AM Thread Starter
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Saga of the Rotten Door

Hi all. I finally finished my door rebuild a while back. It took longer than expected due to the extent of the floor repairs I had to do before I could install the door. I had no choice but to repair the frame as a new door was financially out of the question. Here are a few quick pics of my process. I reproduced the existing frame design to match and used a 2 1/2” ship lap to join. Thanks to Epicfail48 for introducing me to West Systems epoxy (it’s some great sh**t). All the frame parts were painted with some high dollar Sherwin Williams exterior paint before assembly to protect from any (hopefully very little) future exposure. By the way, for those of you buying box store pre-hung doors, they’re made from scrap with finger joints literally every few inches.
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post #2 of 3 Old 11-08-2019, 01:31 AM
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Correct, most jambs are these days get a lot in that also have mdf in them. If you're buying an exterior frame then I'd suggest finding one that joints a synthetic polymer for the last bit. Even stain grade jambs tend to be finger jointed scraps with increasingly thinner veneers. It's rather annoying to be frank.

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post #3 of 3 Old 11-08-2019, 07:24 AM
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That turned out very well for you. It looks pretty much as good as new, so no need to buy a new door anyway, you did a very good job yourself. If you told me you "just" paid for a new door, I would've believed you.
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